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© 14.3.2011 Eigner VPE Folie: 1
Lehrstuhl für Virtuelle Produktentwicklung
Martin Eigner
Complexity Management and PLM
© 14.3.2011, Eigner VPE Folie: 3
Lehrstuhl für Virtuelle Produktentwicklung
Agenda
1 |
3 | External and Internal Variance
…
2 | Solutions for Variant Handling: Neutral and Generic BOM
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
Complexity Management and PLM 2011
1 | Complexity based on Multidisciplinary Products
© 14.3.2011, Eigner VPE Folie: 4
Lehrstuhl für Virtuelle Produktentwicklung
Example Cayenne
Interior Modules: 660
Pipes: 1.200 - 1.500
Pins: 600 bis 2.000
length of pipe: approx..: 2.800 m, 60-70 kg
32 Vehicle-specific Cable Ducts
Source: Porsche AG
Complexity based on more function and higher variation
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 5
Example BOSCH From 1 engine to 2 engines
No Kinematic based on electronically reverse
Dashboard space free
Shift Variance to Software and Electronic
Example BMW
All variants based on the same 2 liter engine
Differentiation based on different SW calibrations
116
118
120
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 6
□ Mechatronic…
□
Mechanik Mechanic
Electronic
IT
Mecha- tronic
IT
Mechanic
Electronic
Mecha- tronic
…yesterday (1968) …tomorrow ???
Source: vgl. [me] 2.2010
When Software and Electronic becomes stronger, why should we use methods from
Mechanic & Hierarchical Requirements and Function Structure?
Software Becomes a Dominant Factor of the Product
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 7
□ Mechatronic Elements
Sensor and Control Unit ECU electronic components
software
control
mechanics
testing / diagnosis
HIL simulation testing
Quelle: BOSCH
Software/Electronic becomes stronger….. Example: Adaptive Cruise Control
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 8
Interdisciplinary Product Design based on an Extended V-Model
Anforderungs-
definition
Produkt-
Planung Entwicklung
Prozess-
planung Produktion Betrieb Recycling
Mechanik
E/E
Software
Dienst-
leistung
…
virtuelle Tests
Eigenschaftsabsicherung
Modellbildung- und Simulation
A/R
F
L
P A/R: Anforderung/Requirements
F : Funktion
L : logische Lösungselemente
P : physikalische Elemente
Integrierte Funktions- und Eigenschaftsabsicherung
(Model Based Design) Modellbildung und Simulation (Simulink, MATLAB, Modelica)
Disziplinenspezifische Modellbildung
(M-CAD, E-CAD, CASE)
Modellbildung, Beschreibung (z.B. in SysML, ModelicaML
physische Tests
hybride Tests
(z.B. HIL)
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 9
Interdisciplinary Product Design requires new Design Methodologies („Pahl/Beitz and Rodenacker for Multidisciplinary Design“)
Functions should move into the foreground instead of Mechanics and Geometry.
Model Based Design as part of Systems Engineering (SE) should be established as an integrative Methodology and a bridge between the different engineering disciplines.
PLM should be the Backbone of the SE approach
Model based Design for Mechatronic Design
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 10
Interdisciplinary Product Design based on an Extended V-Model
Anforderungs-
definition
Produkt-
Planung Entwicklung
Prozess-
planung Produktion Betrieb Recycling
Mechanik
E/E
Software
Dienst-
leistung
…
virtuelle Tests
Eigenschaftsabsicherung
Modellbildung- und Simulation
A/R
F
L
P A/R: Anforderung/Requirements
F : Funktion
L : logische Lösungselemente
P : physikalische Elemente
Integrierte Funktions- und Eigenschaftsabsicherung
(Model Based Design)
Modellbildung, Beschreibung (z.B. in SysML, ModelicaML
physische Tests
hybride Tests
(z.B. HIL)
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 11
Systems Modeling becomes Part of the Engineering
multidisciplinary requirements modeling
360 rotation
360 rotation around point
max speed
collision detection
Original statement
Systeme: Doors, Requisit Pro, XML PLM-Systeme
Left drive
motor
gear
wheel
pinion 1
pinion 2
pinion 3
pinion 4
optic rotation measurement
LED
opt. sensor
ASURO
SE Systeme (SysML, ModellicML)
Multidisciplinary Requirements , Function, Behavior and Building Block Modeling
multidisciplinary E-BOM □ Supporting Systems Modeling
- Combined structures in the early phases of product development
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 12
Example: Requirements for a MicroRobot
□ Engineering of a requirement structure with linked elements
System /Functional BOM
Satisfied by a function
Extracted requirements
Satisfied by a component
Engineering BOM
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 13
Example for concept models (Architecture)
□ System structure
- Block definitions
- Internal structure
Internal structure of the control
<<electronic>>
Internal structure of the drive
<<mechanic>>
Engineering BOM
MircoRobot
Circuit board
…
Drive chassis
Controller
Sensor
motor
gear
wheel
…
…
electronics
mechanics
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 14
CAD/CASE authoring systems
All data in one PDM system
Requirements structure System /Functional BOM (e.g. SysML) Engineering BOM
Product Lifecycle Management (PLM)
Plan Concept Design …
Engineering (authoring systems in concept design, M-CAD, E-CAD, CASE)
Engineering BOM
System structure model
System behavior model
System requirements model
System /Functional BOM
System requirements System structure
System requirements System structure
System behavior
SE as an integrated part of a PLM concept
Requirements management tools
Deriving hierarchical structure information (e.g. via XML)
Requirements structure
F1_300_200_G.ASM
F3_300_211_B.PRT
F3_300_238_F.PRT
…
4XX_200.ASM
L224_300_200_HS.ASM
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 15
Plan Concept Design Validate Production Support
Requirements BOM System /Functional BOM Engineering BOM Simulation/Testing BOM Manufacturing BOM Service BOM
Production Systems
(ERP/MES)
Product Lifecycle Management
(PLM)
Product and Process Backbone Mechatronic
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 16
Interdisciplinary Product Design based on an Extended V-Model
Anforderungs-
definition
Produkt-
Planung Entwicklung
Prozess-
planung Produktion Betrieb Recycling
Mechanik
E/E
Software
Dienst-
leistung
…
virtuelle Tests
Eigenschaftsabsicherung
Modellbildung- und Simulation
A/R
F
L
P A/R: Anforderung/Requirements
F : Funktion
L : logische Lösungselemente
P : physikalische Elemente
Integrierte Funktions- und Eigenschaftsabsicherung
(Model Based Design) Modellbildung und Simulation (Simulink, MATLAB, Modelica)
physische Tests
hybride Tests
(z.B. HIL)
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 17
Tools Modelling and Simulation
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 18
Multidisciplinary modeling and simulation
Programming language for simulation
- Programming language of 4th generation and easy to use
- Textual
For example Matlab, Modelica, …
Graphical modeling
- Modeling graphs with blocks and signals
- Calculation in background
For example Matlab/Simulink, LMS AMESim, …
Component based modeling
- Component view with energy flows
- Model multidomain problems
- Reuse of library elements
For example Matlab/Simulink Simscape, Modelica Standard Library, …
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 19
Description of the inverse pendulum in simulation model
Behavior of components is described in simulations e.g. in Matlab/Simulink
- pendulum and drive kinematics
- Actuators and sensors
- Controler
- Boundary conditions
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 20
Interdisciplinary Product Design based on an Extended V-Model
Anforderungs-
definition
Produkt-
Planung Entwicklung
Prozess-
planung Produktion Betrieb Recycling
Mechanik
E/E
Software
Dienst-
leistung
…
virtuelle Tests
Eigenschaftsabsicherung
Modellbildung- und Simulation
A/R
F
L
P A/R: Anforderung/Requirements
F : Funktion
L : logische Lösungselemente
P : physikalische Elemente
Integrierte Funktions- und Eigenschaftsabsicherung
(Model Based Design)
Disziplinenspezifische Modellbildung
(M-CAD, E-CAD, CASE)
physische Tests
hybride Tests
(z.B. HIL)
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 21
Discipline specific models for example software
Object oriented system and detailed Design (OOD)
Coding and Integration
- Automatic deriving of an skeleton for class definition
- „Programming by pressing a button“ is not realistic
© 14.3.2011, Eigner VPE Folie: 22
Lehrstuhl für Virtuelle Produktentwicklung
Agenda
1 |
3 | External and Internal Variance
…
2 | Solutions for Variant Handling: Neutral and Generic BOM
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
1 | Design Methodology 2.0
Complexity Management and PLM 2011
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 23
The Solution: Neutral or Modular BOM
Environment to define possible neutral structures of a product
Split BOM into a neutral/generic structure,
options and an instantiated structure
To make complexity visible
To reduces the BOM´s 1020-27
down to round about 5000!!! BOM´s
Whiteboard for System Engineers
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 24
Modular (Generic) BOM
Modular BOM - Define options (option categories)
- Create a modular BOM Define the multi-level hierarchy
Assign Items to the modular BOM
Define product logic
- Create an order Assign specification
Derive order specific BOM
- Instantiated BOM´s only on the low level
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 25
Product Family A
Cockpit
Steering column compl.
Dashboard
…
Distance tube
Steering wheel
…
Meters/gages
Dashboard upper part
Dashboard lower part
Airbag
…
(default/standard)
CRUISE=YES
CRUISE=YES & NAVI=YES
Legend
Product Family
Component in GPS
Position Variant with Rule
Item (Assembly or Part) …
Seats
3-spoke Steering Wheel 3004000751
4-spoke St. Wheel w/Cruise & Navi 3005600333
3-spoke Steering Wheel w/Cruise 2015700309
Generic Product Structure in Automotive
Machine Industry can use the same principles to simplify the Product Structure
© 14.3.2011, Eigner VPE Folie: 26
Lehrstuhl für Virtuelle Produktentwicklung
Agenda
1 |
3 | External and Internal Variance
…
2 | Solutions for Variant Handling: Neutral and Generic BOM
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
Complexity Management and PLM 2011
1 | Design Methodology 2.0
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 27
Order Configuration
Customer Smith
Car Type BMW 320i Convertible
Color Black
Extras
- Radio X25
Solution for Product Configuration
Product Structure
Product Configuration (Search for valid Solutions)
Prod. Variants Options
Constraints
…
Attach. parts ext.Attach. parts ext.
Car bodyCar body
……
VehicleVehicle
SeatsSeats
Seat, front leftSeat, front left
Seat cushionSeat cushion
BackrestBackrest
……
Foam0810
Backrest, Sport shape
Vachette leather, Heating1132
Structure7451
Trim cover8786
Foam0810 Foam0810
Backrest, Sport shape
Vachette leather, Heating1132
Backrest, Sport shape
Vachette leather, Heating1132
Structure7451 Structure7451
Trim cover8786 Trim cover8786
Seat rail0912 Seat rail0912
HeadrestHeadrest
ArmrestArmrest
ReclinerRecliner
Seat railSeat rail
...
Foam0812
Backrest, Normal shape
Alcantara1891
Structure7451
Trim cover9700
Foam0812 Foam0812
Backrest, Normal shape
Alcantara1891
Backrest, Normal shape
Alcantara1891
Structure7451 Structure7451
Trim cover9700 Trim cover9700
Armrest, Vachette leather4431
…...
Armrest, Vachette leather4431 Armrest, Vachette leather4431
…... …...
Foam0812
Backrest, Normal shape
Textile1990
Structure7451
Trim cover6541
Foam0812 Foam0812
Backrest, Normal shape
Textile1990
Backrest, Normal shape
Textile1990
Structure7451 Structure7451
Trim cover6541 Trim cover6541
……
Armrest, Alcantara4530
…...
Armrest, Alcantara4530 Armrest, Alcantara4530
…... …...
Armrest, Textile8887
…...
Armrest, Textile8887 Armrest, Textile8887
…... …...
……
...
Deriving individual BOM
…
Attach. parts ext.Attach. parts ext.
Car bodyCar body
……
VehicleVehicle
SeatsSeats
Seat, front leftSeat, front left
Seat cushionSeat cushion
BackrestBackrest
……
HeadrestHeadrest
ArmrestArmrest
ReclinerRecliner
Seat railSeat rail
Foam0812
Backrest, Normal shape
Alcantara1891
Structure7451
Trim cover9700
Foam0812 Foam0812
Backrest, Normal shape
Alcantara1891
Backrest, Normal shape
Alcantara1891
Structure7451 Structure7451
Trim cover9700 Trim cover9700
Headrest, Alcantara2001
…...
Headrest, Alcantara2001 Headrest, Alcantara2001
…... …...
Seat rail0912 Seat rail0912
Foam0813
Seat cushion, Normal shape
Alcantara1820
Structure7452
Trim cover2700
Foam0813 Foam0813
Seat cushion, Normal shape
Alcantara1820
Seat cushion, Normal shape
Alcantara1820
Structure7452 Structure7452
Trim cover2700 Trim cover2700
Armrest, Alcantara4530
…...
Armrest, Alcantara4530 Armrest, Alcantara4530
…... …...
Recliner4502 Recliner4502
Sales
Engineering
Manufacturing
Solution Space
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 28
External Variance
Variance from the customer perspective External Variance
Selection of options leads to individual order-oriented solutions
Constrains determine valid combination of options
Solution Space
Product Configuration (Search for valid soltions))
1027
Order 8037
Selected Options
Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic
- Crypton Light LC0
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 29
Internal Variance
…
Attach. parts ext.Attach. parts ext.
Car bodyCar body
……
VehicleVehicle
SeatsSeats
Seat, front leftSeat, front left
Seat cushionSeat cushion
BackrestBackrest
……
Foam0810
Backrest, Sport shape
Vachette leather, Heating1132
Structure7451
Trim cover8786
Foam0810 Foam0810
Backrest, Sport shape
Vachette leather, Heating1132
Backrest, Sport shape
Vachette leather, Heating1132
Structure7451 Structure7451
Trim cover8786 Trim cover8786
Seat rail0912 Seat rail0912
HeadrestHeadrest
ArmrestArmrest
ReclinerRecliner
Seat railSeat rail
...
Foam0812
Backrest, Normal shape
Alcantara1891
Structure7451
Trim cover9700
Foam0812 Foam0812
Backrest, Normal shape
Alcantara1891
Backrest, Normal shape
Alcantara1891
Structure7451 Structure7451
Trim cover9700 Trim cover9700
Armrest, Vachette leather4431
…...
Armrest, Vachette leather4431 Armrest, Vachette leather4431
…... …...
Foam0812
Backrest, Normal shape
Textile1990
Structure7451
Trim cover6541
Foam0812 Foam0812
Backrest, Normal shape
Textile1990
Backrest, Normal shape
Textile1990
Structure7451 Structure7451
Trim cover6541 Trim cover6541
……
Armrest, Alcantara4530
…...
Armrest, Alcantara4530 Armrest, Alcantara4530
…... …...
Armrest, Textile8887
…...
Armrest, Textile8887 Armrest, Textile8887
…... …...
……
...
Derivation
…
Attach. parts ext.Attach. parts ext.
Car bodyCar body
……
VehicleVehicle
SeatsSeats
Seat, front leftSeat, front left
Seat cushionSeat cushion
BackrestBackrest
……
HeadrestHeadrest
ArmrestArmrest
ReclinerRecliner
Seat railSeat rail
Foam0812
Backrest, Normal shape
Alcantara1891
Structure7451
Trim cover9700
Foam0812 Foam0812
Backrest, Normal shape
Alcantara1891
Backrest, Normal shape
Alcantara1891
Structure7451 Structure7451
Trim cover9700 Trim cover9700
Headrest, Alcantara2001
…...
Headrest, Alcantara2001 Headrest, Alcantara2001
…... …...
Seat rail0912 Seat rail0912
Foam0813
Seat cushion, Normal shape
Alcantara1820
Structure7452
Trim cover2700
Foam0813 Foam0813
Seat cushion, Normal shape
Alcantara1820
Seat cushion, Normal shape
Alcantara1820
Structure7452 Structure7452
Trim cover2700 Trim cover2700
Armrest, Alcantara4530
…...
Armrest, Alcantara4530 Armrest, Alcantara4530
…... …...
Recliner4502 Recliner4502
Orderoriented
BOM
Analysis Rules/Constrains
Options, Rules/Constrains Color = Black, Creme, Grey AirCondition = Basic, Comfort
Rule based Variant-BOM
Definition
Solution Space
Product Configuration (Search for valid soltions))
1027
Order 8037
Selected Options
Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic
- Crypton Light LC0
© 14.3.2011, Eigner VPE Folie: 30
Lehrstuhl für Virtuelle Produktentwicklung
Agenda
1 |
3 | External and Internal Variance
…
2 | Solutions for Variant Handling: Neutral and Generic BOM
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
1 | Design Methodology 2.0
Complexity Management and PLM 2011
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 31
Simplexity
Symplicity means to reach the largest effect with the smallest effort…..
- Albert Einstein
There is no justification for complexity if things could be easy. - Leonardo Da Vinci
Ora Ito, Designer
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 32
Jeffrey Kluger Symplexity
Simplexity: Why Simple Things Become Complex (And How Complex Things Can Be Made Simple) By Jeffrey Kluger WHY are the instruction manuals for cell phones incomprehensible? WHY is a truck driver’s job as hard as a CEO’s? HOW can 10 percent of every medical dollar cure 90 percent of the world’s disease? WHY do bad teams win so many games? Complexity, as any scientist will tell you, is a slippery idea. Things that seem complicated can be astoundingly simple; things that seem simple can be dizzyingly complex. A houseplant may be more intricate than a manufacturing plant. A colony of garden ants may be more complicated than a community of people. A sentence may be richer than a book, a couplet more complicated than a song.
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 33
Simplexity in Art and Design
Ora Ito (born 1977)
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 34
Reducing External Variance
Optimization
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 35
The inevitable Long (Thin) Tail
Varying demand for individual product variants
Reduce Variance
- Eliminate product variants not contributing to commercial success
0
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
Norm
al,
Text
il, (
kein
e),
Manuell
Norm
al,
Text
il, (
kein
e),
El.
Mem
ory
Sport
, Leder,
Heiz
ung, M
anuell
Norm
al,
Text
il, (
kein
e),
Ele
ktrisc
h
Sport
, Leder,
Heiz
ung, E
lekt
risc
h
Sport
, A
lcanta
ra, H
eiz
ung, M
anuell
Norm
al,
Text
il, H
eiz
ung, M
anuell
Norm
al,
Text
il, H
eiz
ung, E
l. M
em
ory
Sport
, A
lcanta
ra, (k
ein
e),
Manuell
Sport
, A
lcanta
ra, H
eiz
ung, E
lekt
risc
h
Sport
, Leder,
(ke
ine),
Manuell
Norm
al,
Text
il, H
eiz
ung, E
lekt
risc
h
Norm
al,
Leder,
Heiz
ung, M
anuell
Norm
al,
Alc
anta
ra, H
eiz
ung, M
anuell
Sport
, A
lcanta
ra, (k
ein
e),
Ele
ktrisc
h
Norm
al,
Leder,
Heiz
ung, E
l. M
em
ory
Norm
al,
Alc
anta
ra, H
eiz
ung, E
l. M
em
ory
Norm
al,
Alc
anta
ra, (k
ein
e),
Manuell
Sport
, Leder,
(ke
ine),
Ele
ktrisc
h
Norm
al,
Alc
anta
ra, (k
ein
e),
El.
Mem
ory
Norm
al,
Leder,
Heiz
ung, E
lekt
risc
h
Norm
al,
Alc
anta
ra, H
eiz
ung, E
lekt
risc
h
Norm
al,
Alc
anta
ra, (k
ein
e),
Ele
ktrisc
h
Norm
al,
Leder,
(ke
ine),
Manuell
Norm
al,
Leder,
(ke
ine),
El.
Mem
ory
Norm
al,
Leder,
(ke
ine),
Ele
ktrisc
h
0
50.000
100.000
150.000
200.000
250.000
300.000
350.000
Stü
ckza
hl
Stü
ckza
hl k
um
mulie
rt
Accum
ula
ted Q
uantity
Quantity
by V
ariant
Product Variants
Example: leather seat without heating
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 36
Picture: Mathias Zagel
The inevitable Long (Thin) Tail
Technical constraints
- Exclude combinations that don’t work
Marketing/product management constraints
- Exclude/enforce combinations to “guide” customer
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 37
Reduce Variance with Constraints
Reduce possible combinations of option values
- Enforce desired combinations
- Avoid undesired combinations
- Reduced external variance of Car Seat, front left: 864 576 (-33%)
- Likewise reduced internal variance of all affected assemblies
SEATS SEA_SPRT (Sport) SEA_NORM (Normal)
SEAT_CVR SAD_VACH (Vachette leather) SAD_ALCN (Alcantara) SAD_TXTL (Textile)
SEAT_HEATING SEA_HEAT (Heating) SEA_none (none)
SEAT_ADJUST SAD_ELM (El. Memory) SAD_ELE (Electrical) SAD_MNL (Manual)
STEERING
STEER_R (RHD) STEER_L (LHD)
DOORS 2DOOR (2 Door) 4DOOR (4 Door)
COL_IN
CLI_BLK (Black) CLI_CRM (Beige) CLI_GRY (Gray)
ARMREST ARM_DRV (Arm rest Driver) ARM_none (none)
exclude
enforce
IT Tool: CONFIGIT
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 38
Reducing Internal Variance
Optimization
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 39
Reduce internal Variance
Assume external variance is fixed
Leverage reuse of parts/assemblies - “Multi functionality”, oversize it
- Utilize symmetry
- Standardize geometry elements
- Decouple interfaces
- Remove functionality
- Relocate functionality
- Shift variation from Mechanic to Electronic and Software
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 40
“Multi Functionality” – Oversize it
Picture: Mathias Zagel
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 42
The new VW modular transverse product platform
Source: Volkswagen Sachsen GmbH
Reduction of combinations of tilt angle and geometric distance from
axle from 36 to 2
Unified engine positioning
Examples for characteristic elements
Standardized position of engine, gearbox, suspension, air
conditioning unit and pedals
Technical length
Standardized fixtures for different types of axles
Standardized fixtures for rear axle
bond control bar
axle Multi control bar
axle
1 2 3
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 44
Decouple Interfaces
Dock connector
© 14.3.2011, Eigner VPE Folie: 46
Lehrstuhl für Virtuelle Produktentwicklung
Agenda
1 |
3 | External and Internal Variance
…
2 | Solutions for Variant Handling: Neutral and Generic BOM
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
1 | Design Methodology 2.0
Complexity Management and PLM 2011
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 47
Variant Strategy
E D C B A
Synergie
E D C B A
Modul Strategy
(Reuse of Parts and Components across Plattforms)
Platform Strategy
.......
.......
Strategic Product Planning
Synergie
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 48
Cost and Benefit of Variants
Quelle: Prof. Dr. Schuh, University of Aachen
Turnover Cost
Optimum
Cost
/ T
urn
ove
r
Variation
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 49
Contact
Martin Eigner
Institute for Virtual Product Development (VPE) University of Kaiserslautern Postfach 3049
D-67653 Kaiserslautern
T +49/172/1524406
F +49/631/205-3872
eigner@mv.uni-kl.de
vpe.mv.uni-kl.de
Thank you
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